Emerson Climate Technologies Gmbh

Copeland Corporation

Emerson Electric Company

Marc Joseph Scancarello

Robert C Stover

Jean-Luc M Caillat

Stephen M Seibel

Roxana E L Ruxanda

Kirk E Cooper

Todd A DeVore

Gary J Diller

Don G Reu

Kenneth P Young

Christopher Stover

William Christian Gates

R Christopher Stover

Christopher S Rice

Brad Anthony Schulze

A light-weight, high-strength insulating compressor component formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure minimizes or reduces transmission of at least one of thermal energy, sound, or vibrational energy through the component. Methods of making such compressor components via additive manufacturing processes are also provided.

Thermal and sound optimized lattice-cored additive manufactured compressor components

A light-weight, high-strength compressor component having at least one fluid delivery feature that is formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure has at least one fluid delivery feature for permitting fluid flow through the body portion of the light-weight, high-strength compressor component. The fluid delivery feature may be a flow channel, a fluid delivery port, a porous fluid delivery feature, or the like that serves to transfer fluids through the component, such as refrigerant and/or lubricant oils. Methods of making such compressor components via additive manufacturing processes are also provided.

Lattice-cored additive manufactured compressor components with fluid delivery features

A light-weight, high-strength compressor component is formed via additive manufacturing that has controlled stiffness and/or deflection levels. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprises the lattice structure in the body portion of the light-weight, high-strength compressor component. The lattice structure may be used to globally or locally control stiffness and/or deflection levels of the compressor component. Additive manufacturing provides flexibility in forming compressor components with desirably improved strength-to-weight ratios while exhibiting high levels of control over stiffness and/or deflection. Methods of making such compressor components via additive manufacturing processes are also provided.

High-strength light-weight lattice-cored additive manufactured compressor components

Methods for making a tribological bearing wear surface for a compressor component are provided. Such methods involve semi-solid metal casting, where an admixture of solid lubricant particles and a metal alloy material is heated to melt the metal alloy material, while the lubricant particles remain in a solid phase. The alloy material and solid lubricant have substantially different densities. The metal alloy material may be a copper, iron, or aluminum alloy, for example. The method further comprises mixing and cooling the admixture to form a semi-solid slurry admixture. Next, the method comprises introducing the semi-solid slurry admixture into a die. Finally, the semi-solid slurry admixture in the die is solidified to form a solid component having the solid lubricant particles homogenously distributed within a metal alloy material matrix, thus forming a metal matrix composite. Compressor components made from such methods are also provided.

Controlled-dispersion of solid lubricious particles in a metallic alloy matrix

A leak detection system for a refrigerant circuit is provided. The refrigerant circuit is sealed and circulates a working fluid having a refrigerant (e.g., flammable refrigerant) and an oil. A reducing tag component is solubilized within the refrigerant. The leak detection system also includes a sensor for detecting the tag component if the refrigerant should leak from the refrigerant circuit. The sensor is highly sensitive to the tag component and thus enhanced detection is enabled. The tag component is stable in the working fluid and does not affect the flammability rating or performance of the refrigerant or oil. The tag component is present at a concentration of from about 50 ppm to about 35,000 ppm in the refrigerant. Methods of detecting leaks from refrigeration systems are also provided.

Leak detector sensor systems using tag-sensitized refrigerants

Scroll members for scroll compressors made from one or more near-net shaped powder metal processes, either wholly or partially fabricated together from sections. In certain variations, the involute scroll portion of the scroll member has a modified terminal end region. The terminal end region may include an as-sintered coupling feature comprising a tip component that forms a contact surface for contacting an opposing scroll member during compressor operation. The tip component can be a tip seal or a tip cap received by the as-sintered coupling feature. The tip cap may be sinter-bonded or otherwise coupled to the terminal end region. In other variations, a terminal end region may comprise a second material including a tribological material that forms a contact surface. Methods of making such scroll members for scroll compressors are also provided.

Powder metal scrolls with modified tip designs

Methods of forming scroll compressor components are provided. The methods include forming at least one component of a scroll member from a powder metallurgy technique and joining the component with another distinct component via a sinter-brazing process. For example, a baseplate having a spiral scroll involute is joined to a hub via a joint interface having brazing material to form a braze joint with superior quality. At least one component is formed from a powder metal material including carbon and at least one species that reacts with or binds carbon to prevent migration during brazing of the sinter-brazing heat process. Optionally, during the powder metallurgy process, an alloy with a lower concentration of carbon is selected, which may be incorporated into a crystal structure with the species that prevents carbon migration.

Powder metal scrolls and sinter-brazing methods for making the same

A scroll component including a spiral scroll wrap, a baseplate having a first major surface coupled to the scroll wrap and a second opposing major surface comprising a protruding pilot extending a distance from the baseplate, and a hub fastened to the baseplate adjacent to the protruding pilot. A method of forming a scroll compressor element is also provided.

Powder metal scroll hub joint

Scrolls made from one or more near-net shaped powder metal processes either wholly or fabricated together from sections. Both 'conventional' press and sinter methods and metal injection molding methods will be described.

Powder metal scrolls

A compressor having a corrosive resistant coating is disclosed. The coating has a first spray coated metallic layer. A sealant layer is disposed over the sprayed metallic coating which has an organic component, a solvent component, and an inorganic phase.

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Troy, OH, United States of America

Marc Joseph Scancarello